US11088184B2 - Array substrate and method of manufacturing the same - Google Patents
Array substrate and method of manufacturing the same Download PDFInfo
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- US11088184B2 US11088184B2 US15/764,341 US201715764341A US11088184B2 US 11088184 B2 US11088184 B2 US 11088184B2 US 201715764341 A US201715764341 A US 201715764341A US 11088184 B2 US11088184 B2 US 11088184B2
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- photosensitive material
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- H01L27/12—Devices consisting of a plurality of semiconductor or other solid-state components formed in or on a common substrate including semiconductor components specially adapted for rectifying, oscillating, amplifying or switching and having potential barriers; including integrated passive circuit elements having potential barriers the substrate being other than a semiconductor body, e.g. an insulating body
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- H01L29/66—Types of semiconductor device ; Multistep manufacturing processes therefor
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Definitions
- a display panel mainly includes a thin film transistor array substrate (TFT), a color filter (CF) substrate, and a liquid crystal layer (LC) disposed between the two substrates.
- TFT thin film transistor array substrate
- CF color filter
- LC liquid crystal layer
- the COA (color filter on array) technology is an integrated technology for forming a color filter layer directly on an array substrate, which may effectively solve problems such as light leakage caused by the alignment deviation in the cell assembly process of the liquid crystal display device, and may significantly increase an aperture ratio of the display.
- the step of forming the first intermediate pattern may include: exposing and developing the transparent photosensitive material layer by using the grayscale mask, to form a completely reserved region of the transparent photosensitive material layer, a first partially reserved region of the transparent photosensitive material layer, a second partially reserved region of the transparent photosensitive material layer and a completely removed region of the transparent photosensitive material layer, wherein the first intermediate pattern includes the completely reserved region of the transparent photosensitive material layer, the first partially reserved region of the transparent photosensitive material layer and the second partially reserved region of the transparent photosensitive material layer.
- the step of forming the second intermediate pattern may include: exposing and developing the black photosensitive material layer by using the grayscale mask, to form a completely reserved region of the black photosensitive material layer, a first partially reserved region of the black photosensitive material layer, a second partially reserved region of the black photosensitive material layer and a completely removed region of the black photosensitive material layer, wherein the second intermediate pattern includes the completely reserved region of the black photosensitive material layer, the first partially reserved region of the black photosensitive material layer and the second partially reserved region of the black photosensitive material layer.
- an orthographic projection of a completely reserved region of the transparent photosensitive material layer of the first intermediate pattern on the base substrate does not coincide with the an orthogonal projection of a completely reserved region of the black photosensitive material layer of the second intermediate pattern on the base substrate
- an orthographic projection of a first partially reserved region of the transparent photosensitive material layer of the first intermediate pattern on the base substrate coincides with an orthogonal projection of a second partially reserved region of the black photosensitive material layer of the second intermediate pattern on the base substrate
- an orthographic projection of a second partially reserved region of the transparent photosensitive material layer of the first intermediate pattern on the base substrate coincides with an orthographic projection of a first partially reserved region of the black photosensitive material layer of the second intermediate pattern on the base substrate.
- the step of processing the first intermediate pattern and the second intermediate pattern by an ashing process may include: completely removing the first partially reserved region of the black photosensitive material layer of the second intermediate pattern to form the organic material pattern, and partially removing the completely reserved region of the black photosensitive material layer of the second intermediate pattern to form the black matrix; and completely removing the completely reserved region of the transparent photosensitive material layer of the first intermediate pattern, completely removing the first partially reserved region of the transparent photosensitive material layer of the first intermediate pattern and the second partially reserved region of the black photosensitive material layer of the second intermediate pattern, to form a via hole between black matrix and the organic material pattern.
- the method may further include: forming a thin film transistor, and forming a passivation layer and a color resist layer; and after the forming a black matrix and an organic insulating pattern on a base substrate, the method further includes forming a pixel electrode.
- an array substrate including a base substrate, a thin film transistor formed on the base substrate, and a black matrix and an organic insulating pattern formed on the base substrate including the thin film transistor, wherein the black matrix and the organic material pattern are provided on an identical layer.
- FIG. 1 is a schematic cross sectional view illustrating an array substrate according to an embodiment of the present disclosure
- FIGS. 2 to 6 are schematic cross sectional views illustrating process steps of forming a black matrix and an organic material pattern layer respectively, according to embodiments of the present disclosure
- FIGS. 7 to 15 are schematic cross sectional views illustrating process steps of a method of manufacturing a thin film transistor of an array substrate respectively, according to embodiments of the present disclosure.
- FIG. 16 is a schematic cross sectional view illustrating a display panel according to an embodiment of the present disclosure.
- spatially relative terms such as “lower”, “above”, “on”, “below” etc. may be used herein to describe the relationship between one element or feature and other elements or features as shown in the figures. It will be understood that the spatially relative terms are intended to encompass different orientations of the device in use or in operation in addition to the orientation depicted in the figures.
- an array substrate may include a base substrate 1 , a thin film transistor formed on the base substrate, and a black matrix 8 and an organic insulating pattern 9 formed on the base substrate 1 including the thin film transistor.
- the black matrix 8 and the organic material pattern 9 are provided in the same layer.
- an array substrate may include: a base substrate 1 ; a gate pattern layer 2 , formed on the base substrate 1 ; a gate insulating layer 3 , formed on the base substrate 1 and covering the gate pattern layer 2 ; an active pattern layer 4 , formed on the gate insulating layer 3 located on the gate pattern layer 2 ; a source electrode S 5 and a drain electrode D 5 , contacting the active pattern layer 4 and partially covering the gate insulation layer 3 respectively; a passivation layer 6 and a color resist layer 7 , formed sequentially on the base substrate 1 on which the source electrode S 5 and the drain electrode D 5 are formed; and a black matrix 8 and an organic material pattern 9 , formed on the base substrate 1 on which the passivation layer 6 and the color resist layer 7 are formed.
- a black matrix 8 and an organic insulating pattern 9 are formed on a base substrate on which a thin film transistor is formed.
- the black matrix 8 and the organic material pattern 9 are formed by using the same mask. The process of forming the black matrix 8 and the organic material pattern 9 will be described below in more detail with reference to the drawings.
- a transparent photosensitive material layer 80 having a predetermined thickness is formed on the formed array substrate 1 ′ (i.e., the base substrate 1 formed with the thin film transistor).
- the transparent photosensitive material layer 80 may be an organic positive photoresist material and may have a thickness of, for example, 20000 ⁇ .
- the transparent photosensitive material layer 80 is exposed and developed by using a grayscale mask 16 , to form a first intermediate pattern 80 ′.
- the grayscale mask 16 includes four regions A 1 to A 4 having different light transmittances from each other. Specifically, the regions A 1 and A 2 of the grayscale mask 16 correspond to the via hole H for connecting the pixel electrode and the active pattern layer 4 on the array substrate.
- the region A 3 of the grayscale mask 16 corresponds to the organic material pattern 9 below the pixel electrode.
- the region A 4 of the grayscale mask 16 corresponds to the black matrix 8 for shielding light above the gate line and the data line.
- the four regions A 1 to A 4 of the grayscale mask 16 have light transmittances of 0%, 30%, 60%, and 100% respectively.
- the formed organic material pattern 80 ′ has four regions having different thicknesses from each other.
- the thicknesses of the four regions are 20000 ⁇ , 14000 ⁇ , 8000 ⁇ , and 0 ⁇ respectively from left to right.
- the value of the light transmittance is only an example, and these regions may have light transmittances of other values different from each other as needed.
- the step of forming the first intermediate pattern 80 ′ includes: exposing and developing the transparent photosensitive material layer 80 by using the grayscale mask 16 , to form a completely reserved region (corresponding to the region A 1 of the grayscale mask 16 ) of the transparent photosensitive material layer 80 , a first partially reserved region (corresponding to the region A 2 of the grayscale mask 16 ) of the transparent photosensitive material layer 80 , a second partially reserved region (corresponding to the region A 3 of the grayscale mask 16 ) of the transparent photosensitive material layer 80 and a completely removed region (corresponding to the region A 4 of the grayscale mask 16 ) of the transparent photosensitive material layer 80 , wherein the first intermediate pattern 80 ′ includes the completely reserved region of the transparent photosensitive material layer 80 , the first partially reserved region of the transparent photosensitive material layer 80 and the second partially reserved region of the transparent photosensitive material layer 80 .
- a black photosensitive material layer 90 having a planar surface is formed on the first intermediate pattern 80 ′.
- the black photosensitive material layer 90 may be a black negative photoresist material and may have a thickness of, for example, 30000 ⁇ .
- the black photosensitive material layer 90 is exposed and developed by using the above grayscale mask 16 , thereby forming a second intermediate pattern 90 ′.
- a region of the second intermediate pattern 90 ′ corresponding to the region A 1 of the grayscale mask 16 is removed, so that the remaining second intermediate pattern 90 ′ has three regions having different thicknesses corresponding to the regions A 2 to A 4 of the grayscale mask.
- the first intermediate pattern 80 ′ and the second intermediate pattern 90 ′ are processed by an ashing process, thereby forming the black matrix 8 and the organic material pattern 9 .
- the step of processing the first intermediate pattern 80 ′ and the second intermediate pattern 90 ′ by an ashing process includes: completely removing the first partially reserved region of the black photosensitive material layer of the second intermediate pattern 90 ′ to form the organic material pattern 9 , and partially removing the completely reserved region of the black photosensitive material layer of the second intermediate pattern 90 ′ to form the black matrix 8 ; and completely removing the completely reserved region of the transparent photosensitive material layer 80 of the first intermediate pattern 80 ′, completely removing the first partially reserved region of the transparent photosensitive material layer 80 of the first intermediate pattern 80 ′ and the second partially reserved region of the black photosensitive material layer 90 of the second intermediate pattern 90 ′, to form a via hole H between black matrix 8 and the organic material pattern 9 .
- the transparent photosensitive material layer is a positive photosensitive material and the black photosensitive material layer is a negative photosensitive material.
- the transparent photosensitive material layer is a negative photosensitive material and the black photosensitive material layer is a positive photosensitive material.
- an organic material pattern layer formed of an organic material is formed between a pixel electrode and a gate line or a data line.
- the introduction of the organic material pattern layer increases a spacing between a pixel electrode and a gate line or a data line, thereby reducing a parasitic capacitance between the pixel electrode and the gate line or the data line, thereby further reducing the power consumption of a display panel of the liquid crystal display.
- the black matrix and the organic material pattern layer may be formed by using an identical mask, the manufacturing cost is reduced.
- an array substrate may further include: a pixel electrode 10 , formed on a base substrate 1 on which a black matrix 8 and an organic material pattern 9 are formed, and electrically connected to a drain electrode D 5 through a via hole H; a planarization layer 11 , formed on the base substrate 1 on which the pixel electrode 10 is formed; and a common electrode 12 , formed on the planarization layer 11 .
- a color resist layer 7 is formed between the passivation layer 6 and the organic material pattern 9 .
- the color resist layer 7 refers to a red/green/blue primary color layer covering the passivation layer 6 .
- An organic material pattern 9 formed of an organic material is formed between a pixel electrode 10 and a gate line or a data line (not shown).
- the introduction of the organic material pattern 9 increases a spacing between a pixel electrode 10 and a gate line or a data line, thereby reducing a parasitic capacitance between the pixel electrode 10 and the gate line or the data line, thereby further reducing the power consumption of a display panel of the liquid crystal display.
- FIGS. 7 to 15 are schematic cross sectional views illustrating process steps of a method of manufacturing a thin film transistor of an array substrate respectively, according to embodiments of the present disclosure.
- a gate pattern layer 2 is formed on a base substrate 1 .
- the base substrate 1 may be an inorganic substrate or an organic substrate, and may be transparent, opaque or translucent.
- the base substrate 1 may be a transparent substrate selected from a glass substrate, a quartz substrate, a transparent resin substrate, or the like, which has a certain firmness and is light-transmitting.
- the gate pattern layer 2 may be formed of a general-purpose electrode material (for example, a metal, an alloy, a conductive metal oxide, a conductive metal nitride, or the like).
- the gate pattern layer 2 may be formed of metal such as titanium (Ti), platinum (Pt), ruthenium (Ru), gold (Au), silver (Ag), molybdenum (Mo), aluminum (Al), tungsten (W), copper (Cu), neodymium (Nd), chromium (Cr), tantalum (Ta), or an alloy including the above metal, or a conductive oxide such as In—Zn—O (Indium Zinc Oxide) (IZO), Al—Zn—O (Aluminum Zinc Oxide) (AZO), In—Sn—O (Indium Tin Oxide) (ITO), Ga—Zn—O (Gallium Zinc Oxide) (GZO) or Zn—Sn—O (Zinc Tin Oxide) (ZTO) or the like.
- a gate material layer may be deposited on, for example, a glass substrate, and then a gate material layer is sequentially subjected to adhesive coating (e.g., positive photoresist), exposing, developing, etching, and lift-off to obtain a gate pattern layer 2 having a desired pattern.
- adhesive coating e.g., positive photoresist
- a gate insulating layer 3 is formed on a base substrate 1 on which a gate pattern layer 2 is formed, and an active pattern layer 4 is formed on the gate insulating layer 3 located on the gate pattern layer 2 .
- the gate insulating layer 3 covering the gate pattern layer 2 may be formed on the base substrate 1 .
- the gate insulating layer 3 may include a silicon oxide (SiO 2 ) layer, a silicon oxynitride (SiO x N y ) layer, or a silicon nitride (Si 3 N 4 ) layer.
- the gate insulating layer 3 may have a structure in which at least two layers of the silicon oxide layer, the silicon oxynitride layer or the silicon nitride layer are stacked.
- the gate insulating layer 3 may have a structure in which the silicon nitride layer and the silicon oxide layer are stacked.
- the silicon nitride layer and the silicon oxide layer may be sequentially disposed on the gate pattern layer 2 .
- the gate insulating layer 3 may be formed of an organic resin material.
- the gate insulating layer 3 having a certain thickness may be formed according to actual needs. In the present disclosure, the thickness of the gate pattern layer 3 is not particularly limited.
- an organic resin material having a thickness may be formed on the base substrate 1 on which the gate pattern layer 2 is formed through various processes such as coating, sputtering, thermal evaporation, chemical vapor deposition, or the like, to form the gate insulating layer 3 . If necessary, the organic resin material may be patterned, to form the gate insulating layer 3 having a predetermined pattern.
- a polysilicon layer having a certain thickness may be deposited on the base substrate 1 on which the gate insulating layer 3 is formed, and then the polysilicon layer may be processed to form the active pattern layer 4 .
- the adhesive coating e.g., a positive photoresist
- exposing, developing, etching, and lift-off may be sequentially performed on the polysilicon, to obtain an active pattern layer 4 having a desired pattern.
- the source electrode S 5 and the drain electrode D 5 may be formed on the base substrate 1 on which the active pattern layer 4 is formed.
- the source electrode S 5 and the drain electrode D 5 that respectively contact the first region and the second region (for example, two ends) of the active pattern layer 4 may be formed on the gate insulating layer 3 .
- Each of the source electrode S 5 and the drain electrode D 5 may have a single-layer structure or a multi-layer structure.
- the material of the source electrode S 5 and the drain electrode D 5 may be the same as or similar to that of the gate pattern layer 2 .
- Each of the source electrode S 5 and the drain electrode D 5 may be formed of the material same as that of the gate pattern layer 2 , or may be formed of the material different from that of the gate pattern layer 2 .
- each of the source electrode S 5 and/or the drain electrode D 5 may be formed of a metal such as Ti, Pt, Ru, Au, Ag, Mo, Al, W, Cu, Nd, Cr, Ta, or an alloy including the above metals, or a conductive oxide such as IZO, AZO, ITO, GZO, or ZTO, or a compound including a conductive oxide.
- a material layer for the source electrode S 5 and the drain electrode D 5 may be deposited on the base substrate 1 on which the active pattern layer 4 is formed, and then the adhesive coating (e.g., a positive photoresist), exposing, developing, etching, and lift-off may be sequentially formed on the material layer, thus obtaining a source electrode S 5 and a drain electrode D 5 having a desired pattern.
- the adhesive coating e.g., a positive photoresist
- a passivation layer 6 and a color resist layer 7 are sequentially formed on the base substrate 1 on which the source electrode S 5 and the drain electrode D 5 are formed.
- a passivation layer 6 covering the active pattern layer 4 , the source electrode S 5 and the drain electrode D 5 may be provided on the gate insulating layer 3 .
- the passivation layer 6 may be a silicon oxide layer, a silicon oxynitride layer, a silicon nitride layer, or an organic layer, or may have a structure in which at least two of the silicon oxide layer, the silicon oxynitride layer, the silicon nitride layer or the organic layer are stacked.
- the passivation layer 6 may have a single-layer structure formed of silicon oxide or silicon nitride, or a multi-layer structure including a silicon oxide layer and a silicon nitride layer disposed on the silicon oxide layer.
- the passivation layer 6 may have a multi-layer structure including two or more layers.
- the passivation layer 6 may include a silicon oxide layer, a silicon oxynitride layer and a silicon nitride layer that are sequentially stacked.
- ranges of the thicknesses of the source electrode S 5 , the drain electrode D 5 and the passivation layer 6 are not limited, and may be changed as needed.
- a color resist layer 7 may be formed on the passivation layer 6 .
- the color resist layer 7 covering the entire passivation layer 6 may be formed on the base substrate 1 on which the passivation layer 6 is formed, that is, red/green/blue color filter blocks are formed.
- the color resist layer 7 may be formed by adhesive coating, exposing, and developing.
- a black matrix 8 and an organic material pattern 9 are formed on a base substrate on which a passivation layer 6 and a color resist layer 7 are formed, wherein the organic material pattern 9 and the black matrix 8 are provided in the same layer.
- the organic material pattern 9 , the black matrix 8 , and the via hole H between the organic material pattern 9 and the black matrix 8 may be formed through the above-described processes.
- the black matrix 8 and the organic material pattern 9 is formed by using the same mask.
- a pixel electrode 10 is formed on the base substrate 1 on which the black matrix 8 and the organic material pattern 9 are formed, and the pixel electrode 10 is electrically connected to the drain electrode D 5 through the via hole H.
- a metal oxide layer for example, an ITO layer
- a process of adhesive coating positive photoresist
- exposing, developing, ashing, etching, and lift-off may be performed, thereby forming the pixel electrode 10 having a predetermined pattern.
- a planarization layer 11 is formed on a base substrate 1 on which a pixel electrode 10 is formed.
- One or more materials of the acrylic resin, epoxy resin, phenol resin, polyamide resin, polyimide resin, unsaturated polyester resin, polyphenylene ether resin, polyphenylene sulfide resin, and benzocyclobutene (BCB) may be used to form the planarization layer 11 .
- a common electrode 12 is formed on the planarization layer 11 .
- the metal oxide layer ITO layer
- a process of adhesive coating positive photoresist
- exposing, developing, ashing, etching, and lift-off may be performed, thereby forming the common electrode 12 .
- the array substrate manufactured through the above steps is combined with another substrate (which may be a substrate described above, such as the glass substrate), a spacer 13 is disposed therebetween and the liquid crystal 15 is injected therebetween, thereby forming a display panel for, for example, a liquid crystal display.
- another substrate which may be a substrate described above, such as the glass substrate
- a spacer 13 is disposed therebetween and the liquid crystal 15 is injected therebetween, thereby forming a display panel for, for example, a liquid crystal display.
- the present disclosure further provides a display panel including the array substrate described above.
- the present disclosure further provides a method of manufacturing a display panel, the method including the array substrate manufactured according to the method described above.
- the method of manufacturing a display panel further includes: combining the manufactured array substrate with another substrate, with a spacer disposed therebetween; and forming a liquid crystal layer between the array substrate and said another substrate.
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PCT/CN2017/101906 WO2018141156A1 (en) | 2017-02-04 | 2017-09-15 | Array substrate and fabrication method therefor |
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CN107045237B (en) | 2017-02-04 | 2022-02-15 | 合肥京东方光电科技有限公司 | Array substrate and manufacturing method thereof |
CN208848008U (en) * | 2018-10-29 | 2019-05-10 | 惠科股份有限公司 | Substrate and display panel |
CN110262145A (en) * | 2019-06-11 | 2019-09-20 | 惠科股份有限公司 | Array substrate, manufacturing method of array substrate and display panel |
CN111487794B (en) * | 2020-05-12 | 2023-04-07 | Tcl华星光电技术有限公司 | Manufacturing method of display panel |
US12074583B2 (en) * | 2021-05-11 | 2024-08-27 | X Display Company Technology Limited | Printing components to adhesive substrate posts |
CN114355659B (en) * | 2022-03-21 | 2022-06-14 | 南昌虚拟现实研究院股份有限公司 | Manufacturing method of optical display device based on array substrate structure |
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US20200266220A1 (en) | 2020-08-20 |
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